Automated Systems and Methods for Combining Cards and Products

ABSTRACT

According to various aspects, exemplary embodiments are disclosed of an automated system for combining cards and products for packaging. Also disclosed are exemplary automated methods for combining cards and products for packaging. In an exemplary embodiment, an automated system for combining cards and products generally includes a card station and a merge station. The card station is configured to form a card to a desired shape for combining with a product. The card station includes at least one roll former operable to fold at least a portion of the card. The merge station is configured to receive the formed card from the card station and combine the formed card with the package.

CROSS-REFERENCE TO RELATED APPLICATION

This U.S. non-provisional patent application claims the benefit of and priority to U.S. provisional patent application No. 61/751,799 filed Jan. 11, 2013. The disclosure of the application identified in this paragraph is incorporated herein by reference in its entirety.

FIELD

The present disclosure generally relates to automated systems and methods for combining cards and products, for example, for packaging.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Products are oftentimes sold in packages. For example, products are sometimes shrink wrapped in or as a package.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

According to various aspects, exemplary embodiments of automated systems and methods for combining cards and products for packaging are disclosed. In one exemplary embodiment, an automated system for combining cards and products generally includes a card station and a merge station. The card station is configured to form a card to a desired shape for combining with a product. The card station includes at least one roll former operable to fold at least a portion of the card. The merge station is configured to receive the formed card from the card station and combine the formed card with the package.

In another exemplary embodiment, an automated method generally includes operations of applying glue to a portion of a card at a card station for use in coupling the card to a product; forming the card at the card station to a desired shape, based on a shape of the product; conveying the formed card to a merge station; conveying the product to the merge station; positioning the formed card in a desired orientation in the merge station to receive the product; and pressing the glue to a surface of the product, to thereby combine the card and the product.

In another exemplary embodiment, an automated system generally includes a card station configured to form a card to a desired shape for combining with a product, where the card station has a first roll former operable to fold a first portion of the card and a second roll former operable to fold a second portion of the card, to thereby form the card to a desired shape, and a guide configured to position the formed card in a desired orientation for combining with the product. The system also includes a merge station configured to receive the formed card from the card station and combine the formed card with the package, and a feed station configured to isolate the product from multiple products, and transport the isolated product to the merge station.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a block diagram of an exemplary embodiment of an automated system for combining cards and products according to the present disclosure;

FIG. 2 is a perspective view of a card station, a feed station, and a merge station of the system of FIG. 1;

FIG. 3 is a top plan view of the card station, the feed station, and the merge station of FIG. 2;

FIG. 4 is an enlarged perspective view of a portion of the card station of FIG. 2;

FIG. 5 is an enlarged perspective view of a roll former of the card station of FIG. 2; and

FIG. 6 is an enlarged perspective view of a portion of the merge station of FIG. 2.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Disclosed herein are exemplary embodiments of automated systems and methods for combining cards with products. Examples of cards include (without limitation) paper cards, cardboards, J-cards, U-boards, backer-boards, protective sleeves, cards made from other materials, other cards, cards configured for covering end portions of products (e.g., automotive air filters, other products, etc.), etc. The cards may be blank, or they may include information about the products, advertising, or other information. In some aspects, the cards may also provide support/protection to the products, for example, when shipping, storing, etc. the products.

Exemplary embodiments of systems and methods of the present disclosure generally place a card around a leading end portion of a product (e.g., a rectangular end of the product, a square end of the product, another portion of the product, etc.). As the card and product combine (e.g., merge), the card is squared to the leading end portion of the product, both vertically and horizontally. The combined product and card can then be subsequently processed, as desired, for example, shrink wrapped, or otherwise processed. This accurate merging of the product and the card can provide for a very nice, clean, marketable final product, and can allow operators of the systems and methods to take full advantage of significant cost reductions of packaging, transportation, labor, and material.

In various exemplary embodiments, systems generally include various stations (or areas) of operation that work together, simultaneously, to combine cards and products. In various aspects, the stations/areas include automated components that can be programmed to perform desired operations (e.g., form cards to desired shapes, direct products to the formed cards, merge the formed cards with the products, direct the merged products and cards to subsequent possessing stations/areas, subsequently process the merged products and cards, etc.). In addition, the various stations (or areas) can be programmed to work together, with all (or substantially all, or at least some) of the movements being automated and/or synchronized, for example, by a system program logic controller (PLC) program. As an example, product sizes can be entered into a touchscreen, and adjustment scale settings may be displayed for operators of the systems to use for setting up the systems for various products. As such, product width, length, and height dimensions can be handled by the systems within maximum and minimum parameters. Once product dimensions are entered, adjustment scale settings (e.g., three adjustment scale settings, etc.) are displayed to the operators for any given product that falls within the product ranges.

In various exemplary embodiments, systems generally include card stations (e.g., U-board forming dual lug conveyor areas, etc.) for forming cards to desired shapes, for merging with products. The card stations generally include card feeders that operate to feed various cards into the card stations, and conveyors that feed the cards through the card stations. Glue applicators and roll forming areas may also be provided in the card stations. As an example, cards can be fed singularly, from the card feeders, into empty dual height lug pockets along the conveyors, and then the conveyors can index the cards forward, one lug spacing at a time. As the cards advance from the lug spaces, with lugs pushing the cards, the glue applicators dispense glue onto the cards (at desired locations on the cards). As the cards further advance, they index through roll formers, which gently fold the cards to desired shapes (e.g., form flaps of the cards; form the cards to “J” shapes, “U” shapes, other desired shapes, etc.; etc.). As the folded cards are advanced further, flaps of the cards are guided to desired positions (broadly, the cards are oriented) to allow for precise combining of products with the folded cards.

In various exemplary embodiments, systems also (or alternatively) generally include feed stations for directing, delivering, etc. products to folded cards, and then for directing, delivering, etc. combined cards and products to subsequent processing operations. The feed stations may include one or more of roller conveyors, lug conveyors, belt conveyors, indexing systems, indexing product stops, and product take away conveyors. As an example, products to be merged with cards can be fed from an indexing accumulation system that holds back products (e.g., on a minimum pressure accumulation conveyor using a singulation unit, etc.) until desired for combining with the cards. To singulate the products for combining, a gate (broadly, a stop, etc.) (e.g., of a singulation unit, etc.) may be used to selectively allow passage of the products. In so doing, the products can be indexed to combine with pre-folded waiting cards (e.g., from a card station, etc.). Once the products are placed into the cards, the combined products and cards can be indexed toward a take away conveyor which, for example, may feed them to a wrapping station (e.g., shrink wrappers), or to other processing areas, etc.

In various exemplary embodiments, systems also (or alternatively) generally include merge stations for combining products and folded cards. The merge stations may include stops and/or presses for use in conforming, combining, merging, etc. pre-folded cards to products (e.g., aligning the products and the cards, fitting the cards to the products, adhering the cards to the products, etc.).

In various exemplary embodiments, systems generally include combinations of card stations, feed stations, and merge stations. For example, in some exemplary embodiments, systems may generally include both card stations and merge stations. In other exemplary embodiments, systems may include card stations, feed stations, and merge stations. In other exemplary embodiments, systems may include one or more of card stations, feed stations, and merge stations, and one or more different and/or additional stations.

In various embodiments, methods generally include forming cards to desired shapes, for example, at card stations, etc., based on shapes of products to be combined with the cards. Methods may also include feeding isolated products, for example, using a feed station, etc., to a merge station for combining with pre-folded cards. In some aspects, glue may be applied to portions of the cards to help couple the cards to the products.

As will be appreciated, exemplary embodiments of the systems and methods of the present disclosure can accommodate different desired sizes of cards for use with desired products (e.g., via manual operation, via automated operation, via adjustment of components of the systems, via operation of the PLC program, etc.). For example, cards may vary both by length and width because of various product possibilities.

With reference now to the drawings, FIGS. 1-6 illustrate an exemplary embodiment of an automated system 100 embodying one or more aspects of the present disclosure. The system 100 is configured to combine cards (see exemplary cards 101 in FIGS. 2 and 3) and products for packaging. Any suitable cards may be used with the system 100 (e.g., cardboards, J-cards, U-boards, backer-boards, protective sleeves, other cards, etc.). In addition, the cards may be blank, or they may include information about the products, advertising, or other information. In some aspects, the cards may also provide support/protection to the products, for example, when shipping, storing, etc. the products. Further, any suitable products may be used in (or processed by) the system 100 (e.g., automotive air filters, other products, etc.).

As shown in FIGS. 1-3, the illustrated system 100 generally includes a card station 102, a feed station 104, and a merge station 106. The feed station 104 is configured to isolate a product from multiple products, and transport the isolated product to the merge station 106. The card station 102 is configured to form a card to a desired shape for combining with the product at the merge station 106. And, the merge station 106 is configured to receive the formed card, from the card station 102, and combine the formed card with the isolated product. The combined card and product can then be transported, via the feed station 104, from the merge station 106 to a packaging station 108 (FIG. 1), for further processing. The packaging station 108 can include any suitable station for further processing the combined card and product, and may include, as an example, one or more apparatus capable of packaging the combined card and product. For example, the packaging station 108 may include a wrapping apparatus configured to shrink wrap the combined card and product.

The card station 102 of the system 100 generally includes a card feeder 110 and a conveyor 112. The card feeder 110 is operable to provide the cards to the conveyor 112, and the conveyor 112 is operable to move the cards through the card station 102. The card feeder 110 may include any suitable apparatus for feeding, delivering, providing, etc. the cards into the system 100, such as, for example, a friction card feeder, etc. The conveyor 112 includes a dual lug conveyor, having pairs of first and second lugs 114, 116 disposed on a belt drive for moving (e.g., pushing, etc.) the cards through the card station 102 (e.g., via a stepper motor, other drive source, etc.). Pockets (e.g., spacings, etc.) are defined between each pair of the lugs 114, 116 for receiving the cards from the card feeder 110, with each pocket configured to receive a single card. The lugs 114, 116 then operate to move the cards, positioned within the pockets, through the card station 102. In the illustrated embodiment, the first and second lugs 114, 116 of each pair have different heights, with the first lug 114 being generally shorter than the second lug 116. It should be appreciated that lug conveyors having more than or fewer than two lugs may be used with the conveyor 112, and/or lug conveyers having groups (e.g., pairs, etc.) of lugs with similar heights may be used. Further, in some embodiments, conveyors other than lug conveyors may be used.

With additional reference to FIGS. 4 and 5, the card station 102 also includes a glue applicator 118 and first and second roll formers 120, 122 located along the conveyor 112. The glue applicator 118 is configured to apply glue (e.g., one or more dots of glue, etc.) to one or more desired portions of the card, for coupling the card to the product (at the merge station 106). Any suitable glue applicator 118 may be used within the scope of the present disclosure. Once the glue is applied to the card, the roll formers 120, 122 are each configured to fold, bend, etc. at least a portion of the card, to thereby form the card to a desired final shape, for example, a “J” shape, a “U” shape, etc.

As shown in FIG. 5, the first roll former 120 includes a first series of rollers, each roller indicated at 124, and a second series of rollers, each roller indicated at 126. The first series of rollers 124 operate to hold a central portion of the card generally horizontally in the pocket of the conveyor 112 as the conveyor 112 moves the card through the roll former 120. The second series of rollers 126, which gradually change (e.g., consecutively change, etc.) in orientation, then operate to fold a portion of the card to a desired position as the card moves through the roll former 120. For example, in the illustrated embodiment, the first roll former 120 is configured to fold a right side portion of the card generally upwardly (e.g., about ninety degrees, etc. to form a first flap, etc.).

The second roll former 122 is similar to the first roll former 120, but with the first and second rollers generally reversed. As such, in the illustrated embodiment, the second roll former 122 is configured to fold a left side portion of the card generally upwardly (e.g., about ninety degrees, etc. to form a second flap, etc.).

As shown in FIG. 2, a guide 128 is provided in the card station 102, generally after the second roll former 122, to help position the folded card in a desired orientation for precise combining with a product in the merge station 106. The illustrated guide 128 includes a ramp portion that operates to push the folded side portions of the card generally downwardly, as the folded card moves from the card station 102 to the merge station 106. This allows the product to move generally into the folded card, without interference from the folded side portions, and also positions the folded side portion of the card having the glue generally over the product when received in the card. In other embodiments, guides may include structures other than ramps such as, for example, actuators, etc. for positioning, orienting, aligning, etc. the folded cards in desired positions to receive the products.

With reference again to FIGS. 2 and 3, the feed station 104 of the system 100 includes a conveyor 130 configured to transport products to be combined with the folded cards through the system 100. An in-feed portion 130 a of the conveyor 130 is configured to receive the products from a supply 132 of the products (FIG. 1) (e.g., a source of the products, a bin of the products, a product feeder, etc.), and transport the products to the merge station 106. And, a take away portion 130 b of the conveyor 130 is configured to transport combined cards and products from the merge station 106 to the packaging station 108, after the cards and products are combined.

The in-feed portion 130 a of the conveyor 130 includes a roller deck 134 and a lug conveyor 136. The roller deck 134 includes multiple rollers configured to allow the products received from the supply 132 to easily move (e.g., via gravity, momentum, forces applied to the rollers, etc.) to a singulation unit 138 of the feed station 104, where the products are isolated. The roller deck 134 also allows the singulation unit 138 to hold back, accumulate, etc. products with minimum pressure. The lug conveyor 136 includes spaced apart lugs 140 disposed on a belt drive for moving (e.g., pushing, etc.) the isolated products, along rollers, from the singulation unit 138 to the merge station 106 (e.g., via a stepper motor, other drive source, etc.). Pockets are defined between each of the lugs 140 for receiving the isolated products from the singulation unit 138, with each pocket configured to receive a single product. The lugs 140 then operate to move the products, positioned within the pockets, to the merge station 106. In the illustrated embodiment, the lug conveyor 136 also includes guides 142 disposed generally toward side portions of the lug conveyor 136 for centering the products within the pockets. In some aspects, the guides 142 are adjustable to help accommodate different sizes of products. With that said, it should be appreciated that lug conveyors having more than one lug at each location along the lug conveyor may be used. Further, in some embodiments, conveyors other than lug conveyors may be used.

The singulation unit 138 of the feed station 104 isolates (or singulates) individual products received from the supply 132 of products. In the illustrated embodiment, the singulation unit 138 includes a stop 144 (e.g., an overhead gate, etc.) and a sensing device 146 (e.g., a photo eye; a camera, an infra-red device; other suitable identifying, sensing, etc. devices; etc.). The sensing device 146 operates to sense location of the products in the singulation unit 138. And, the stop 144 is then moveable (e.g., generally vertically, etc.), based on location information from the sensing device 146, to selectively block and allow movement of the products from the singulation unit 138 to the lug conveyor 136. As such, individual products are allowed to pass (e.g., are indexed, etc.) by the stop 144 and into the pockets of the lug conveyor 136, one at a time. As an example, a line of multiple products may be provided to the feed station 104 from the supply 132 of products. At the singulation unit 138, the stop 144 selectively retracts up to allow accumulated products (e.g., products accumulated behind the stop 144 when the stop 144 is down, etc.) to advance to the lug conveyor 136. The first product in the line may get sped up to create a gap between it and the next product. This product may be timed to be placed in front of the lug 140 that will index it through the system 100 before that lug 140 moves up to the conveying surface. After the gap is sensed, for example, by the sensing device 146, the stop 144 may go back down and stop the other products from advancing until the stop 144 is signaled to retract up again.

The take away portion 130 b of the feed station conveyor 130 includes a lug conveyor 148 and a belt conveyor 150. The lug conveyor 148 includes spaced apart lugs 152 disposed on a belt drive for moving (e.g., pushing, etc.) the combined cards and products, along rollers, from the merge station 106 to the belt conveyor 150 (e.g., via a stepper motor, other drive source, etc.). Pockets are defined between each of the lugs 152 for receiving the combined cards and products from the merge station 106, with each pocket configured to receive a single card and product. The lugs 152 then operate to move the combined cards and products, positioned within the pockets, to the belt conveyor 150. The belt conveyor 150 then operates to transition the combined cards and products to the packaging station 108. Again, it should be appreciated that lug conveyors having more than one lug at each location along the lug conveyor may be used. Further, in some embodiments, conveyors other than lug conveyors may be used.

With additional reference now to FIG. 6, the merge station 106 of the system 100 is disposed generally between the in-feed portion 130 a of the feed station conveyor 130 and the take away portion 130 b of the feed station conveyor 130. The merge station 106 includes a stop 154 (e.g., an overhead gate, blade, etc.) and a press 156, operable to combine the folded cards from the card station 102 with the isolated products. The stop 154 is moveable (e.g., generally vertically, etc.) relative to the feed station conveyor 130 to selectively block and allow movement of the products. For example, when the stop 154 is in position to block movement of a product (e.g., when the stop 154 is generally down, etc.), a formed card from the card station 102 is moved into position, and generally centered, against the stop 154, directly in front of an advancing product. The product is then moved into the formed card, thereby aligning the card with the product generally horizontally and/or vertically. At this time, the stop 154 holds the product and card together, generally still, and allows the press 156 to impact an upward facing portion of the card and contact the glue to the product (thereby coupling the card to the product). The stop 154 then raises, and the merged product and card are indexed to the take away portion 130 b of the feed station conveyor 130, as a package. As soon as the trailing end of the product is clear, the stop 154 lowers and a waiting pre-folded card is again indexed directly in front of the stop 154.

In the illustrated embodiment, the press 156 includes a spring-loaded bar 158 that is moveable generally vertically to selectively impact the card. In addition, the press 156 can be vertically adjusted, as desired, to account for different product sizes. And, the press 156 is configured to provide sufficient pressure to the card to sufficiently adhere the card and the product. Further, in some aspects, the press 156 helps guide the card into position, relative to the stop 154, in preparation for merging the card with a product. In other embodiments, other suitable presses may be used, to couple cards and products together.

With reference again to FIG. 1, a control 160 is provided for controlling and/or coordinating operations of the system 100. For example, the card station 102, the feed station 104, and the merge station 106 may be programmed to work together, generally simultaneously, to combine the card and product, with all (or substantially all or at least some) of the actions of the stations 102, 104, 106 being automated and/or synchronized, for example, by a system program logic controller (PLC) program. As an example, sizes/dimensions of the products to be processed by the system 100 can be entered into a touchscreen of the control 160, and adjustment scale settings may be displayed for operators of the system 100 to use for setting up the system 100 for the products. Product width, length, and height dimensions can be handled by the system 100 within maximum and minimum parameters. Once the product dimensions are entered, adjustment scale settings (e.g., three adjustment scale settings, etc.) are then displayed to the operators for any given product that falls within the product ranges. In some embodiments, the control may also be configured to control the supply of products and/or the packaging station 108.

In an exemplary operation of the illustrated system 100, a card is fed singularly from the card feeder 110 into an empty pocket in the conveyer 112, and the conveyor 110 then indexes the card forward (with the lugs 114, 116 both pushing the card). As the card advances toward the merge station 106, the glue applicator 118 initially dispenses glue dots onto a top, right side portion of the card (as viewed in FIG. 2). The lugs 114, 116 then move the card through the first roll former 120, which folds the right side portion (broadly, a first portion) of the card, with the glue dots, generally upward (e.g., about ninety degrees to generally form a first flap, etc.). The second lug 116 then advances the folded card through the second roll former 122, which folds a left side portion (broadly, a second portion) of the card generally upward (e.g., about ninety degrees to generally form a second flap, etc.) and forms the card into its final shape (e.g., a “J” shape, a “U” shape, etc.). As the folded card is advanced further, the guide 128 moves the upper flaps of the card down and, at the appropriate time, delivers, indexes, etc. the card to the stop 154 in the merge station 106 (generally in front of a product to be merged with the card).

At about the same time, the feed station 104 isolates an individual product, at the singulation unit 138, and delivers the isolated product into a pocket in the lug conveyor 136. The isolated product then proceeds down the lug conveyor 136 to the merge station 106, where it is placed into the waiting card at the stop 154 and squared. The press 156 impacts the cards and seats the glue dots against the product, and the stop 154 then moves to allow the combined card and product to move to the packaging station 108 (via the take away portion 130 b of the feed conveyor 130). As can be seen, the card station 102, the feed station 104, and the merge station 106 are configured to operate substantially simultaneously.

It should be appreciated that the system 100, and the stations 102, 104, 106 thereof, may have any suitable dimensions within the scope of the present disclosure. For example, an overall length of the automated system 100 (as measured from one end of the feed station conveyor 130 to the other) may be about 190 inches. A width of the automated system 100 (as measured from the card feeder 110 to one end of the merge station 106) may be about 143 inches. A width of the card station 102 may be about 40 inches, and a width of the feed station conveyor 130 may be about 29 inches. Further, a length of the in-feed portion 130 a of the feed station conveyor 130 may be about 102 inches, and a length of the take away portion 130 b of the feed station conveyor 130 may be about 47 inches. Other example embodiments may have other dimensions without departing from the scope of the present disclosure.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. In addition, advantages and improvements that may be achieved with one or more exemplary embodiments of the present disclosure are provided for purpose of illustration only and do not limit the scope of the present disclosure, as exemplary embodiments disclosed herein may provide all or none of the above mentioned advantages and improvements and still fall within the scope of the present disclosure.

Specific dimensions, specific materials, and/or specific shapes disclosed herein are example in nature and do not limit the scope of the present disclosure. The disclosure herein of particular values are not exclusive of other values that may be useful in one or more of the embodiments disclosed herein.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The term “about” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. For example, the terms “generally,” “about,” and “substantially,” may be used herein to mean within manufacturing tolerances. Or for example, the term “about” as used herein when modifying a quantity of an ingredient or reactant of the invention or employed refers to variation in the numerical quantity that can happen through typical measuring and handling procedures used, for example, when making concentrates or solutions in the real world through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients employed to make the compositions or carry out the methods; and the like. The term “about” also encompasses amounts that differ due to different equilibrium conditions for a composition resulting from a particular initial mixture. Whether or not modified by the term “about,” the claims include equivalents to the quantities.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements, intended or stated uses, or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 

What is claimed is:
 1. An automated system for combining cards and products for packaging, the system comprising: a card station configured to form a card to a desired shape for combining with a product, the card station having at least one roll former operable to fold at least a portion of the card; and a merge station configured to receive the formed card from the card station and combine the formed card with the product.
 2. The system of claim 1, further comprising a guide configured to position the formed card in a desired orientation for combining with the product.
 3. The system of claim 1, wherein the merge station includes a stop configured to position the formed card in the merge station and combine the formed card with the product.
 4. The system of claim 1, further comprising a glue applicator configured to apply glue to a portion of the card for coupling the card to the product.
 5. The system of claim 4, further comprising a guide configured to position the formed card in an orientation for combining with the product, such that the glue contacts at least part of the product when the card is combined with the product.
 6. The system of claim 5, further comprising a press configured to contact the card when combining the card with the product to thereby contact the glue with the at least part of the package.
 7. The system of claim 1, wherein the card station includes a card feeder and a conveyor, the conveyor operable to move the card from the card feeder to the at least one roll former, and move the formed card from the at least one roll former to the merge station.
 8. The system of claim 7, wherein the conveyor includes at least one lug configured to contact the card and move the card from the card feeder to the at least one roll former and from the at least one roll former to the merge station.
 9. The system of claim 8, wherein the at least one lug includes first and second lugs configured to contact the card and move the card, the first lug having a different height than the second lug.
 10. The system of claim 1, further comprising a feed station configured to isolate the product from multiple products, and transport the isolated product to the merge station.
 11. The system of claim 10, wherein the feed station includes a feed conveyor configured to transport the isolated product to the merge station.
 12. The system of claim 10, wherein the feed station includes a simulation unit having a stop and a sensing device for isolating the product from the multiple products.
 13. The system of claim 1, further comprising a packaging station configured to receive a combined card and product and shrink wrap the combined card and product.
 14. The system of claim 1, wherein the at least one roll former includes a first roll former operable to form a first portion of the card, and a second roll former operable to form a second portion of the card.
 15. An automated method of combining a card and a product for packaging, the method comprising: applying glue to a portion of a card at a card station for use in coupling the card to a product; forming the card at the card station to a desired shape, based on a shape of the product; conveying the formed card to a merge station; conveying the product to the merge station; positioning the formed card in a desired orientation in the merge station to receive the product; and pressing the glue to a surface of the product, to thereby combine the card and the product.
 16. The method of claim 15, further comprising conveying the combined card and product to a packaging station.
 17. An automated system for combining cards and products for packaging, the system comprising: a card station configured to form a card to a desired shape for combining with a product, the card station having a first roll former operable to fold a first portion of the card and a second roll former operable to fold a second portion of the card, to thereby form the card to a desired shape, and a guide configured to position the formed card in a desired orientation for combining with the product; a merge station configured to receive the formed card from the card station and combine the formed card with the package; and a feed station configured to isolate the product from multiple products, and transport the isolated product to the merge station.
 18. The system of claim 17, wherein the card station further includes a glue applicator configured to apply glue to a portion of the card for coupling the card to the product; and wherein the merge station includes a press configured to contact the card when combining the card with the product to thereby contact the glue with the at least part of the package.
 19. The system of claim 18, wherein the card station further includes further comprising a guide configured to position the formed card in an orientation for combining with the product, such that the glue contacts at least part of the product when the card is combined with the product.
 20. The system of claim 17, wherein the first roll former includes a first series of rollers and a second series of rollers, and wherein the second series of rollers gradually change in orientation to thereby fold the first portion of the card. 